For many years, Thomas Cappellaro played a key role in transmission development at ZF. Now retired, he still helps out as and when required.

KEEPING IT BRIEF

  • Thomas Cappellaro co-developed the first electronic transmission control system. 
  • He tested every vehicle himself that carried components he developed.
  • His first boss and mentor was Friedrich Scheiber.
  • Today, Thomas helps out on refurbishing his initial designs.
Thomas Cappellaro is the brains behind many of the ZF powershift transmissions you’ll have operated.

“Back then, mechanical engineers were afraid of electricity,” says the former ZF design engineer, as he describes the atmosphere in the 1980s. Born in 1959, he studied precision engineering in Munich, a blend of mechanical and electrical engineering now known as mechatronics. After starting out on his career at Webasto, he moved to ZF in Passau in 1985.

A Passau native, he found his career calling in ZF’s experimental department — electro-hydraulic control systems for powershift and continuously variable transmissions in construction and agricultural machinery. He oversaw these projects from conception to functioning prototypes, one of which was the full powershift Schlüter Super Tronic 2200 TVL or the stepless Super 1900 TVL. However, Schlüter was far from Thomas’s only client, as he worked on other tractor and self-propelled machinery projects with other manufacturers.

John Deere was another of the world’s major tractor players for whom Thomas and his team developed transmission and axle components. This picture was taken in 1993.

Into the nitty gritty of a gearbox

He was one of the first developers to log into a tractor transmission with a laptop. After playing a pioneering role in introducing electronics to the world of transmissions, he became head of ZF’s axle testing department in 1989. This position involved developing four- wheel-drive axles with suspension for tractors and also road vehicles. 

After seven years in axle development, he returned in 1996 as a group leader to his favourite field of work: transmissions. Under his leadership, the ZF T7000 gearbox with its six ranges and four and six powershift steps was created. This was used by Deutz-Fahr, Fendt and Steyr. 

The Deutz-Fahr Agrotron 115 and the Steyr 9115 both used a ZF gearbox; the powershift for the Fendt Favorit 515 also came from Passau.

Thomas Cappellaro and his team placed a particular emphasis on powershuttle boxes. In 2001, he became head of R&D and testing of mechanical gearboxes and rear axles.

Thomas pictured at Zoomlion in 2015, when ZF was producing transmission components for the Chinese manufacturer.

From 2018 until his well earned retirement in 2022, he was Senior R&D Manager for drive systems on mobile working equipment and electrical, hydraulic and mechanical components for mobile working equipment systems.

The display is part of the transmission on the Schlüter Super Tronic 1900 TVL designed by ZF.

Worldwide traveller

During his time at ZF, Thomas collaborated with almost every tractor manufacturer in the world and drove every machine that used one of his developments. An important aspect was working alongside engine makers to integrate the transmission into the overall powertrain.

Pauny is an Argentinian manufacturer for whom ZF developed transmissions under the leadership of Thomas Cappellaro.

A particular achievement for Thomas was his early understanding of the mechanical limitations of a gearbox which can only be overcome with electronics. It was he and his colleagues that not only ensured ZF was competitive in a challenging market, but also helped transform it into becoming a major player in the industry. 

Thomas learned a lot from his first boss at ZF, Friedrich Scheiber. Here the two engineers are pictured at Agritechnica 2009.

Thomas Cappellaro is still grateful today for the trust placed in him by his first boss, test manager Friedrich Scheiber, and the support of his colleagues at the ZF sites in Passau and Friedrichshafen on Lake Konstanz. He says these are the people who provided him with the necessary tools and taught him the skills he needed to develop transmissions, to the point that he was widely referred to as Mr Powershift.

This is how the transaxle arrived at ZF’s testing department before being installed in a tractor.

Helper for special projects

The transmission expert doesn’t know how many tractor and other machines have been built with his inventions and developments that are still running today. Over the years, however, he has built up a private archive and has already helped out many owners of vintage vehicles or workshops by providing drawings, part numbers and settings. Even in his retirement, he still enjoys doing this, although the feedback rate could be higher. Still, he wouldn’t have become Mr Powershift, if he’d been reliant on receiving external thanks and recognition.

Wilfried Holtmann, Maria Henkemeier

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